Can rejected units exceed inspected units?

No. The rejected count must be a subset of the inspected population. Check that both records cover the same lot and decision point.

Why round the target count downward?

The target is a maximum. Rounding upward could permit a whole rejection count whose percentage exceeds the entered target.

Does rework change this rate?

Use a consistent decision point. Initial rejection and final disposition after rework describe different populations and should be reported separately.

Does a rate below target prove the process meets it?

No. It describes this inspected population. Statistical evidence about an underlying process rate requires an appropriate sampling and uncertainty analysis.

Quality & Metrology calculator

Observed Rejection Rate Calculator

Compare rejected units with inspected units and translate your rejection-rate target into a maximum whole rejection count.

What this calculator does

Compare rejected units with inspected units and translate your rejection-rate target into a maximum whole rejection count.

Formula used

Observed rejection rate = rejected units ÷ inspected units × 100
Rate headroom = maximum rejection rate − observed rejection rate
Maximum whole rejections = round down(inspected units × target percentage ÷ 100)
Excess rejections = max(0, rejected units − maximum whole rejections)
Accepted units = inspected units − rejected units

Inputs explained

Rejected Units: Whole units rejected at this inspection decision.
Inspected Units: Whole units covered by the same acceptance decision.
Maximum Rejection Rate: Maximum rejection percentage, entered in increments of 0.0001 percentage points.

How to use the result

Best suited to a lower Rejection-Rate Target, a higher Rejection-Rate target.
This observed sample rate does not establish the underlying population rate. Defect counts are different when one rejected unit contains several defects.

Current U.S. benchmarks

U.S. manufacturing runs at 75.7% of capacity (Federal Reserve, Aug 2026). New factory orders are up 8.5% year over year (Census).

Common questions

Can rejected units exceed inspected units? No. The rejected count must be a subset of the inspected population. Check that both records cover the same lot and decision point.
Why round the target count downward? The target is a maximum. Rounding upward could permit a whole rejection count whose percentage exceeds the entered target.
Does rework change this rate? Use a consistent decision point. Initial rejection and final disposition after rework describe different populations and should be reported separately.
Does a rate below target prove the process meets it? No. It describes this inspected population. Statistical evidence about an underlying process rate requires an appropriate sampling and uncertainty analysis.

Last reviewed 2026-10-06.